Rail bond



- E. M. DEEMS Dec. 24, 1935.

RAIL BOND Filed July 11, 1934 INVENTOR 6. ATTORN Patented Dec. 24 1935UNITED STATES RAIL BOND Edward M. Deems, Forest Hills, N. Y., assignorto Railroad Accessories Corporation, New York, N. Y., a corporation ofNew York Application July 11, 1934, Serial No. 734,579

6 Claims.

This invention relates to conductors, more especially to conductors forconnecting the adjacent ends of railway rails, particularly those foruse in connection with railway track circuits.

5 It is well understood by those skilled'in the railway signalling art,that a track circuit includes an isolated section of the trackway formedby placing insulating joints in each of the lines of rails, and byconnecting a battery across the 10 rails at one end, and a relay across,the rails at the other end.

It is also well understood that the ordinary rail connecting or fishplates connecting the adjacent ends of the ordinary thirty-six footsect-ions are 15 not to be relied upon to'furnish sufficientconductivity for the electrical energy which flows in the rails from thebattery at one end of the section to the relay at the other end thereof.This fact has necessitated a special bonding of each I 20 of theadjacent abutting rail ends within the- 30 method of bonding exposes thebonding wires to mechanical injury, in that, they may become entangledwith dragging partsvfrom the rolling stock, or may actually get onto thetop of the.

rail, and so be severed bythe passage thereover 35 of the wheels ofrolling stock. In addition, they are very likely to be damaged by trackmen while working along the track, particularly when work-.

ing in and about the rail joint, and more especially when tightening thebolts thereof, or replacing the fish plates with new plates.

A very pronounced difficulty with the old'type of bond is, that due toits length and in spite of its size as it may be commercially used,it-does not oifer a conductivity as great'as is desired. 45 The desiredconductivity cannot be attained without enlarging the bond to aprohibitive 'extent.

Attempts have been madeto increase the conductivity and decrease themechanical disadvam. 50 tages of bonds by applying a bond directly tothe rail heads. Such a bond can be very short, as compared with thepreviously described bond,

therefore, for a given diameter havea'n increased conductivity in thatit has less resistance. Such 55 bonds have, in general, been applied to'the head rail heads.

of the rail by electrical or flame welding. Many competent engineers areadverse to applying any considerable degree of heat to the side of theball of a rail, especially adjacent the end thereof, and thisreluctance, considered by many to be- 5 well founded, hasmilitated'against the use of such bonds.

A further difliculty which has been met with in the type of bond applieddirectly to the rail heads is that it is particularly exposed to injuryby snow ploughs and ballast spreaders. Both of these devices, andespecially the ballast spreader, have parts which extend below the topsurface of the head of the rail on the outside thereof. These parts, dueto the swaying of the vehicle, come in contact with the head of railbonds and destroy them.

Attempts have been made to attach bonds to rail heads by drilling acavity in the rail head and attaching the bond to a plug driven into thecavity. Adifficulty with this type of bond arises from the fact that itis necessary to drill a relatively deep hole in the head of the rail.This hole penetrates what might be' called the active load bearingcross-sectional area of the head and to that extent weakens the railhead.

In my copending application Serial No. 538,943,

filed May 21, 1931, I have illustrated, described and claimed a type ofbond for attachment to This type of bond obviates many of the defects ofthe types of bonds heretofore used and has many desirable virtuesespecially in'that the cavity which must be formed in the head of therail for the reception thereof is so shallow that it does not penetratethe active load sustaining cross-section of the rail. By reason of thisfact, incipient cracks which may develop in the rail head are notafforded an easy oppor tunity to spread by reason of the cavity formed.for the reception of the head of the rail bond, as 0 that cavity doesnot closely approach the'point of origin of the cracks.

I have discovered, in practice, that the type of bond illustrated anddescribed in my copending application, hereinbefore referred to, has aweakness in that it is subject to injury at the junction line of thesurfacein which the cavity is produced and the bond. This weakness hasbeen cured by me through the'adoption of the structure of bond as shownby my copending application Serial No. 600,595, filed March 23, 1932,now Patent No. 1,945,480 granted January 30,: 1934.

A principal object of this invention is to provide a bond of the typeillustrated, described and placehaving that difference in diameter whichmay well occur in practice due to the difference in the drills used,either as to their original size or because of the particular grindingthereof A further object of the invention is the production of a bondof. the type specified which will be of such construction that it may bemore readily removed from the cavity in the rail head or other place inwhich it is positioned.

Other objects and advantages will appear as the descriptionof theparticular physical embodiments selected to illustrate the inventionprogresses, and the novel features will be particularly pointed out inthe appended claims.

Indescribing the invention in detail and the particular physicalembodiments selected to illustrate the invention, referencewill be hadto the accompanying drawing, and the several views thereon, in whichlike characters of reference designate like parts throughout the severalviews, and in which:

Figure 1 is a fragmentary vertical sectional view of a portion of railhead with a portion of a bond embodying my invention in place therein;Fig. 2 is a fragmentary view illustrating a side elevation of thearrangement as shown by Fig. 1;

Fig. 3 is a part section, part elevation illustrating the initialposition of the plug portion of my bond as it is being driven intoacavity in a rail head; Fig. 4 is a view similar to Fig. 1 but showing amodified form; Fig. 5 is a side elevational view showing the formillustrated by Fig. 4; Fig. 6 is a view similar to Fig. 3 but showingthe form of bond illustrated by Fig. 4; Fig. '7 is a view similar toFig. 1 but illustrating a further modified form ofbond; Fig. 8 is a sideelevational view similar to Fig. 2 of the bond as illustrated by .Fig.I; Fig. 9 is a view corresponding to Fig. 3 but showing the bondillustrated by Fig, .7; Fig. 10 is a view corresponding to Fig. 1 butillustrating a modified form; Fig. 11 is a side elevation correspondingto the side elevation, Fig. 2, but show-' ing the bond as illustrated byFig. 10 Fig..12 is a view corresponding to Fig. 3 but illustrating thebond of Fig. 10; Fig. 13 is a cross-sectional view of the bond as shownby Fig. 10 but in a plane at a right angle t5 the plane of section ofFig. 10.

In Fig. 1 a fragment of a rail head I is shown. This rail head fragmentl as shown in Fig. l'has a cavity 2 formed therein. This cavity isformed, as shown, by using the usual form of drill and consequently itwill vary in its diameter. High grade drills made by reputablemanufacturers are, of course, extremely close to size, but if they arenot ground properly they will drill over-size holes, consequently, thecavity 2, substantially circular in; outline, may have a diametercorresponding exactly to the desired diameter or it may be larger,

In order to provide the plug portion, as 3, of a bond which willproperly fit into'cavities made in rail heads, notwithstanding the usualvariation in sizes thereof, applicant has provided the plug portion 3 ofa bond with an over-size portion.

This over-size portion in Fig. 3 is the frustrum of a cone, designatedas the entering head I. This head has a top face 5 which has a diameterpref-' erably much less than the diameter of the cavity 2 and has a base6 which is larger in diameter than the diameter of the cavity 2. Thecylindrical body portion 1 is preferably a shade less in diameter thanthe diameter of the cavity 2. A driving head 8 is attached, asintegrally, to the cylindrical portion 1.

. The plug 3 is formed of metal. It is formed of a metal which will flowsomewhat under pressure. It is preferably formed of soft copper,although mild steel works very satisfactorily, in any event, the metalshould be somewhat plastic when cold. When a plug,-such as 3, ofsubstantially the di- 1:, mensions as shown is positioned in the openingof a cavity 2, and then blows are applied to the head 8 the corners 9 ofthe frustrum of a cone 4 are displaced and caused to flow along thecylindrical portion 1 of the plug, so that, as the plug 3 enters intothe cavity 2 it just fits the cavity 2 and is thereby guided so as toalign its longitudinal axis with thelongitudinal axis of the cavity 2,and when the top 5 of the frustrum of the cone contacts with the basewall "of the cavity 2, it 25 spreads out and fills the space so that ifthe diameter of. the cavity 2 closely approximates the diameter of thecylindrical portion 1 of the plug 3, the final position of the partswill be as shown in Fig. 1, that is, the plug 3 will completely ml 30the cavity 2, as illustrated by Fig. 1, with a shoulder ll spaced aslight distance from the edge -of the rail I.

The space between the side of the rail I and the shoulder H affords anopportunity to place a a two pronged tool between the rail and theshoulder of the plug and by a leverage action pull the plug out, of thecavity. This is often necessary because of the destruction of some partof'the bond. 40 As is well understood the plug portion 3 with itsassociated head 3 is always used in pairs, one

being positioned in one rail head, the other being positioned in anadjacent rail head, the two being connected by an electrical conductor.This 45 is well known in the art and is fully shown in my copendingapplication Serial No. 538,943 filed May 21, 1931 and in applicationSerial No. 647,308, filed December 15, 1932.

In the case of the present plug 3, provision is 5 made for the conductorto the other plug of the pair by forming a slot II in the driving headand inserting therein lamina l'3 which may be held tightly in positionin any .usual or approved man-- nor as by rivets IQ and ii and/or bysoldering orsa by welding. I

Although applicant's plug 3 is suitable for a standard size cavity 2, italso is suitable for an over-size cavity 2, because applicant alwaysmakes the base 6 of the frustrum of a cone I of greater (:0 diameterthan any diameter of the cavity 2 which .occurs even with the most*u'nskillful grinding of drills which will ocgzur in practice when thecavity2 is sumciently over-size, the cylindrical portion I will notcontact entirely along the wall 65 portion l9 of the plug there is acylindrical portion 20 larger in diameter than the cylindrical portionIQ of the plug, or to put it in another way, the cylindrical portion IQof the plug is smaller in diameter than the cavity 2. When this plug isdriven the final result is as shown by Fig. 4, that is, the plug bearsupon the circular inside surface of the cavity 2 from the line 2| to theline 22 so that the edge 23 of the cavity is not in contact with theplug. This is advantageous, because the point of contact between theedge 23 of the cavity and the plug is a line of weakness in the plugarising from the constant vibration to which the plug is subjected inpractice. It is at this point that the plugs may break off. Byseparating the edge 23 from the plug, the breakage is obviated. Not onlyis the breakage obviated, but by making the parts of such dimensionsthat the length of the surface between the lines 2] and 22 is asdesired, any particular firmness of hold may be obtained, that is, aplug may be in contact with such an amount of surface of the cavity 2,that it is very difficult to withdraw the plug, or it may be in contactwith such a small amount of surface of the cavity 2, that it may bewithdrawn fairly readily. This difference in action may be easilyregulated by regulating the length and diameter of the cylindricalportion 20 of the plug.

In the form of plug as shown by Figs. 4, 5 and 6, the conductor to beattached to the companion plug is fitted into a central bore 24 of theplug and lies in a slot 25 of the head. Whenthe plug is driven into thecavity 2, the walls of the plug are squeezed inwardly and firmly holdthe conductor 26, making intimate mechanical and electrical contacttherewith. 1 In Figs. '7, 8 and 9 another modified form of plug isshown. This plug 27 may be constructed, insofar as its conical head 28and cylindrical portion 29 is concerned, just exactly like the plug inFig. 6 has its corresponding parts H and 2!! formed, but the conductor30 for connection to the companion plug is positioned in a longitudinalslot 3i and a transverse slot 32. When the plug 2'! is driven, the wallsof the plug are squeezed inwardly and make intimate mechanical andelectrical contact with the conductor 30 which like the plug is usuallymade of fairly soft copper.

The form of bond shown in Figs. 10, 1'1 and 12 is, as regards the coneshaped end, the cylindrical portion adjacent thereto and the drivinghead, the same as the cone shaped end H, the cylindrical portion 20, andthe driving head of the plug of Fig. 6, but the conductor 33 connectingthe plug to the companion plug lies in two parallel slots longitudinalof the plug, one of which is designated 34 and the other of which isdesignated 35. When this form of plug is driven into a cavity as 2, theplug acts just as does the plug l6 of Figure 6 and the walls thereofcollapse somewhat and make intimate mechanical and electrical contactwith the portions 36 and 31 of the conductor 33, and in addition theconductor 33 at the portion 38 is forced into intimate mechanical andelectrical contact with the body of the rail head i.

Each of the forms of plugs shown in Figs. 4 to 13 inclusive is providedwith a driving head, that is, the portion 39 in Fig. 4; the portion 40in Fig. '7; and the portion H of Fig. 10. Each of the driving headsforms a shoulder as 42 in Fig. 4;

43 in Fig. 6; and 44 in Fig. 10. Between the-side of the rail I and theshoulder onthe plug a two ,pronged tool may be positioned so as tostraddle the cylindrical portion such as IQ of Fig. 6 and then be usedas a lever to withdraw the plug from the cavity in which it has beenpressed.

The plugs of applicant's invention are suitable for many situationswhere an electrical conductor must be mechanically and electricallyattached to a metal body. They are peculiarly adapted for connection ,ofan electrical conductor to railway track structures such as rails,switches, fish plates and the like, but they are particularly valuablefor use in bonding railway rails for track circuit purposes where thehighest possible conductivity at the lowest possible cost is desired,and they are especially valuable in use as that type of bond known, asrail head to rail head bond,.in which the complete bond is not much oversix inches in length and preferably not over about four and one halfinches in length and in which the plugs are inserted in cavities drilledin the side of the rail head,- as illustrated in my prior applicationhereinbefore referred to. They are particularly valuable where thecavity, as 2, is formed in the substantially non-load bearingcross-section of the rail, as explained in my application Serial No.647,308, filed December 15, 1932, that is, where all of the material tothe left of the line 45 of Fig. l i

1 is substantially non-load bearing, so that the cavity 2 is all orsubstantially all in that portion of the rail head which issubstantially non-load bearing so that the formation of the cavity 2does not conduce to the formation of incipient cracks.

Although I have particularly described several particular physicalembodiments of my invention and explained the operation, constructionand principle thereof, nevertheless, I desire to have it understood thatthe forms selected are merely illustrative but do not exhaust thepossible physical embodiments of the idea of means underlying myinvention.

What I claim as new and desire to secure Letters Patent of the UnitedStates, is:

1. A plug'for electrically and mechanically attaching a conductor to ametal body, the plug formed of a somewhat plastic metal, and formed withan entering head and with a driving head connected by a body portionsubstantially cylindrical and less in diameter than the diameter of thedriving head or the diameter of the largest portion of the enteringhead, said entering head comprising a flaring portion with the smallestdiameter at the tip end of the entering head and the largest diameteradjacent the body, said largest diameter portion of the flaring headbeing greater in diameter than the cavity into which the plug is to bedriven whereby a.portion of the "flaring head will be caused to flowalong the body portion upon driving the plug into a cavity, said drivinghead providing a shoulder whereby a means is provided for removing theplug from a cavity by the insertion of a tool between the body in whichthe cavity is formed and the shoulder.

' 2. In a. plug for insertion into a cavity in a body adjacent the endof the body portion; a flaring portion adjacent the larger diametercylindrical portion having its largest diameter adjacent the cylindricalportion and its smaller diameter at the end of the plug; a driving headon the other end of the body portion, said driving head being -of largerdiameter than the cylindrical portion thereby affording a shoulder; saidparts all formed with a bore therethrough and said head formed with aslot communicating with the bore whereby a metallic conductor may bepositioned therein for connection by the plug..

3. In a plug for insertion into a cavity in a body for making intimatemechanical and electrical contact between the body and conductor, havinga substantially cylindrical body portion somewhat less in diameter thanthe cavity into which the plug is to be placed; a cylindrical portion ofsomewhat larger diameter than the body portion adjacent the end oithebody portion; a flaring portion adjacent the larger diameter cylindricalportion having its largest diameter adjacent the cylindrical portion andits smallest diameter at the end of the plug; a driving head on theother end of the body portion, said driving head being of largerdiameter than the cylindrical portion-thereby affording a shoulder; andmeans for connecting an electrical conductor to said plug. v

4. In a plug for insertion into a cavity in body for making intimatemechanical and electrical contact between the body and a conductor,having a substantially cylindrical body portion somewhat less indiameter than the cavity into which the plug is to be placed; acylindrical portion of somewhat larger diameter than the body portionadjacent the end of the body portion; a flaring portion adjacent thelarger diameter cylindrical portion having its largest diameter adjacentthe cylindrical portion and its smallest diameter at the end of theplug; a driving head on the other end of the body portion, said drivinghead being of larger diameter than the cylindrical portion therebyaflording a shoulder; said plug. being formed with an orificetherethrough and a transverse slot in the flaring portion whereby A aconductor may be connected thereto by positioned therein.

5. In a plug for insertion into a cavity in a body for making intimatemechanical and elecbeing trical contact between the body and aconductor,

ing head being of larger diameter than the cylin drical portion therebyaffording a shoulder; said plug being formed with two parallel orificeslongitudinal thereof connected by a transverse slot in the flaringportion whereby a conductor may be connected thereto.

6 In a plug for driving into a cavity for connecting a conductor to ametal body in a circular cavity formed in the. metal body which consistsof a substantially cylindrical body smaller in diameter than thediameter of the cavity, and having a head thereon at the end firstentering the cavity having in part a diameter greater than the diameterof the cavity, and such portion being of such length longitudinally ofthe plug that when the plug is driven into the cavity it will contactthe circular portion thereof for only a portion of its distance; andmeans for connecting the conductor to the plug.

7 EDWARD M. DEEMS.

